Air filter for turbochargers and superchargers

ABSTRACT

An apparatus and a method are provided for an air filter configured to be mounted onto air inlets of turbochargers and superchargers. The air filter comprises a proximal base including an inlet receiver configured to receive an air inlet, a clamp to secure the air inlet within the inlet receiver, and a first opening aligned with a screw mechanism of the clamp. A filter medium fastened to the proximal base is configured to remove particulate matter and other contaminates from an incoming air stream. A distal end cap fastened to the filter medium comprises a second opening aligned with the first opening. A conduit within an interior cavity of the air filter is disposed between the first opening and the second opening, facilitating tightening and loosening the clamp by extending an appropriate tool through the interior cavity so as to engage the screw mechanism of the clamp.

PRIORITY

This divisional application claims the benefit of and priority to U.S.patent application Ser. No. 15/453,808 filed on Mar. 8, 2017 and U.S.Provisional Application, entitled “Air Filter for Turbocharger andCentrifugal Supercharger,” filed on Mar. 9, 2016 having application Ser.No. 62/305,709.

FIELD

The field of the present disclosure generally relates to air filters.More particularly, the field of the invention relates to an apparatusand a method for an air filter configured to be coupled with air inletsof turbochargers and superchargers.

BACKGROUND

A turbocharger is generally a turbine-driven, forced induction deviceconfigured to increase the efficiency and power of an engine. Ascompared to a naturally aspirated engine, a turbocharged engine producesgreater output power because the turbine forces more air, andproportionately more fuel, into the engine's combustion chambers thanatmospheric pressure alone. As will be appreciated by those skilled inthe art, turbochargers were once referred to as “turbosuperchargers”when all forced induction devices were classified as “superchargers.” Atpresent, however, the term “supercharger” typically is used in referenceto only mechanically driven, forced induction devices, such as by way ofa belt, gear, shaft, or chain connected to the engine's crankshaft,whereas the term “turbocharger” is used in reference to a turbine drivenby the engine's exhaust gas.

Turbochargers find wide use with truck, car, train, aircraft, andconstruction equipment engines. Turbochargers typically are used withOtto cycle and Diesel cycle internal combustion engines; although morerecently, turbochargers have also been found to be useful withautomotive fuel cells. One drawback, however, is a lack of specializedor a dedicated line of air filters available for turbochargers andcentrifugal superchargers. It will be appreciated that turbochargers andcentrifugal superchargers tend to present severe space constraintswithin engine compartments, thereby limiting the sizes and shapes ofpotential air filters. Many users rely on short cone-shaped air filtersthat are designed for other engine applications. Some users resort tomaking their own screen covers for the turbocharger air inlet.

Those skilled in the art will recognize that the shape of a housing ofthe turbocharger or supercharger, referred to as a “snail,” presentsunique challenges. An inlet receiver of the air filter must be insetinto a scroll of the turbocharger or supercharger, thus requiring theuser to expose the base of the air filter in order to access and tightena clamp of the air filter. This encourages the user to apply force tothe air filter in an attempt to expose the base, potentially damagingthe air filter in the process. Consequently, another drawback is thatconventional air filters are not easily installable onto turbochargersand superchargers without potentially damaging the air filters. What isneeded, therefore, is an air filter which fits tightly onto air inletsof turbochargers and superchargers without the base of the air filterhaving to be exposed during installation of the air filter.

SUMMARY

An apparatus and a method are provided for an air filter configured tobe mounted onto air inlets of turbochargers and superchargers. The airfilter comprises a proximal base including an inlet receiver configuredto receive an air inlet, a clamp to secure the air inlet within theinlet receiver, and a first opening aligned with a screw mechanism ofthe clamp. A filter medium fastened to the proximal base is configuredto remove particulate matter and other contaminates from an incoming airstream. In some embodiments, the filter medium comprises paper, foam,cotton, spun fiberglass, or other known filter materials, woven ornon-woven material, synthetic or natural, or any combination thereof. Insome embodiments, the filter medium comprises a filter oil compositionto enhance air cleaning properties of the filter medium. A distal endcap fastened to the filter medium comprises a second opening alignedwith the first opening. A conduit within an interior cavity of the airfilter is disposed between the first opening and the second opening,facilitating tightening and loosening the clamp by extending anappropriate tool through the interior cavity so as to engage the screwmechanism of the clamp. The conduit facilitates guiding the tool throughthe interior cavity to the screw mechanism while also serving to preventunfiltered air from entering through the first opening and the secondopening into the air inlet.

In an exemplary embodiment, an air filter configured to be mounted ontoair inlets of turbochargers and superchargers comprises a proximal baseconfigured to support the air filter and provide an interface betweenthe air filter and an air inlet of a turbocharger or a supercharger, theproximal base comprising an inlet receiver configured to receive the airinlet, a clamp configured to secure the air inlet within the inletreceiver, and a first opening aligned with a screw mechanism of theclamp; a filter medium fastened to the proximal base and configured toremove particulate matter and other contaminates from an incoming airstream; a distal end cap fastened to the filter medium and comprising asecond opening aligned with the first opening; and a conduit within aninterior cavity of the air filter and disposed between the first openingand the second opening; wherein the first opening and the second openingfacilitate tightening and loosening the clamp by extending anappropriate tool through the interior cavity by way of the conduit so asto engage the screw mechanism of the clamp.

In another exemplary embodiment, the filter medium is comprised ofpaper, foam, cotton, spun fiberglass, or other known filter materials,woven or non-woven material, synthetic or natural, or any combinationthereof. In another exemplary embodiment, the filter medium is pleatedor otherwise shaped or contoured to increase a surface area for passingthe air stream to be cleaned. In another exemplary embodiment, thefilter medium comprises a filter oil composition to enhance air cleaningproperties of the filter medium.

In another exemplary embodiment, the distal end cap is comprised of amaterial which is sufficiently hard so as to retain the filter medium ina desired configuration and support the air filter when coupled to theair inlet of the turbocharger or the supercharger. In another exemplaryembodiment, the conduit is configured to guide an appropriate toolthrough the interior cavity to the screw mechanism. In another exemplaryembodiment, the conduit prevents unfiltered air from entering throughthe first opening and the second opening into the air inlet.

In another exemplary embodiment, the clamp comprises a metal bandincluding a perforated portion which is received by the screw mechanism,the perforated portion being configured to receive a worm gear, or othersimilar component within the screw mechanism capable of engaging theperforated portion, such that turning the worm gear accordingly tightensor loosens the metal band. In another exemplary embodiment, the screwmechanism is configured with a substantially perpendicular orientationwith respect to the circumference of the metal band, therebyfacilitating engaging the screw mechanism with an appropriate tool byway of the first opening and the second opening.

In an exemplary embodiment, an air filter configured to mount onto anair inlet of a turbocharger comprises a base comprising an inletreceiver configured to couple with the air inlet; a filter mediumcoupled to the base and configured to remove particle contaminates fromair drawn into the air inlet; a cap coupled to the filter medium; aconduit within an interior cavity of the air filter and disposed betweena first opening in the base and a second opening in the cap; and a clampconfigured to secure the air inlet within the inlet receiver, the clampbeing operable by way of the first opening, the conduit, and the secondopening.

In another exemplary embodiment, the clamp further comprises a screwmechanism aligned with the first opening, the conduit, and the secondopening so as to facilitate operation of the clamp by way of a suitabletool passed through the cap, the conduit, and the base. In anotherexemplary embodiment, the screw mechanism is configured to enabletightening and loosening of the clamp by way of the suitable tool. Inanother exemplary embodiment, the conduit is configured to guide thesuitable tool through the interior cavity to the screw mechanism. Inanother exemplary embodiment, the conduit is configured to preventunfiltered air from entering through the first opening and the secondopening into the air inlet.

In an exemplary embodiment, a method for an air filter to mount onto airinlets of turbochargers and superchargers comprises configuring a basecomprising an inlet receiver to couple with an air inlet, the baseincluding a first opening; fastening a filter medium to the base, thefilter medium configured to remove particle contaminates from air drawninto the air inlet; fastening a cap to the filter medium opposite of thebase, the cap including a second opening; extending a conduit from thefirst opening in the base to the second opening in the cap; configuringa clamp to secure the air inlet within the inlet receiver; and placingthe clamp onto inlet receiver.

In another exemplary embodiment, extending the conduit further comprisespositioning the conduit within an interior cavity of the air filter,such that unfiltered air is prevented from entering through the firstopening and the second opening into the air inlet. In another exemplaryembodiment, configuring the clamp further comprises configuring a screwmechanism of the clamp which is operable by way of a suitable toolpassed through the second opening in the cap, the conduit, and the firstopening in the base. In another exemplary embodiment, placing the clampfurther comprises aligning the screw mechanism with the first opening,the conduit, and the second opening so as to facilitate operation of theclamp by way of the suitable tool.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings refer to embodiments of the present disclosure in which:

FIG. 1 illustrates an upper perspective view of an exemplary embodimentof an air filter configured to be mounted onto an air inlet of aturbocharger or a supercharger;

FIG. 2 illustrates a lower perspective view of an exemplary embodimentof an air filter configured to be mounted onto an air inlet of aturbocharger or a supercharger;

FIG. 3A illustrates a lower cross-sectional view of the air filterillustrated in FIG. 1, taken along a line 3A-3A;

FIG. 3B illustrates a cross-sectional view of the air filter illustratedin FIG. 1, taken along a line 3B-3B;

FIG. 4 illustrates a perspective view of an exemplary embodiment of aclamp configured to mount an air filter onto an air inlet of aturbocharger or a supercharger;

FIG. 5 illustrates an upper perspective view of an exemplary useenvironment wherein a screw driver is extended through an interiorcavity of an air filter so as to adjust a clamp, whereby the air filteris mounted onto an air inlet of a turbocharger or a supercharger; and

FIG. 6 illustrates an upper perspective view of an exemplary useenvironment wherein a wrench is used to turn a driver extending throughan interior cavity of an air filter so as to adjust a clamp, whereby theair filter is mounted onto an air inlet of a turbocharger or asupercharger.

While the present disclosure is subject to various modifications andalternative forms, specific embodiments thereof have been shown by wayof example in the drawings and will herein be described in detail. Theinvention should be understood to not be limited to the particular formsdisclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth inorder to provide a thorough understanding of the present disclosure. Itwill be apparent, however, to one of ordinary skill in the art that theinvention disclosed herein may be practiced without these specificdetails. In other instances, specific numeric references such as “firstclamp,” may be made. However, the specific numeric reference should notbe interpreted as a literal sequential order but rather interpreted thatthe “first clamp” is different than a “second clamp.” Thus, the specificdetails set forth are merely exemplary. The specific details may bevaried from and still be contemplated to be within the spirit and scopeof the present disclosure. The term “coupled” is defined as meaningconnected either directly to the component or indirectly to thecomponent through another component. Further, as used herein, the terms“about,” “approximately,” or “substantially” for any numerical values orranges indicate a suitable dimensional tolerance that allows the part orcollection of components to function for its intended purpose asdescribed herein.

In general, the present disclosure describes an apparatus and a methodfor an air filter configured to be mounted onto air inlets ofturbochargers and superchargers. The air filter comprises a proximalbase configured to support the air filter and provide an interfacebetween the air filter and an air inlet of a turbocharger or asupercharger. The proximal base comprises an inlet receiver configuredto receive the air inlet, a clamp configured to secure the air inletwithin the inlet receiver, and a first opening aligned with a screwmechanism of the clamp. A filter medium is fastened to the proximal baseand configured to remove particulate matter and other contaminates froman incoming air stream so as to prevent them from entering into the airinlet. A distal end cap is fastened to the filter medium and comprises asecond opening aligned with the first opening. A conduit within aninterior cavity of the air filter is disposed between the first openingand the second opening. The first opening and the second openingfacilitate tightening and loosening the clamp by extending anappropriate tool through the interior cavity by way of the conduit so asto engage the screw mechanism of the clamp.

FIGS. 1-3 illustrate an exemplary embodiment of an air filter 104configured to be mounted onto an air inlet of a turbocharger or asupercharger (hereinafter “turbocharger”). As illustrated in FIGS. 1-2,the air filter 104 comprises a proximal base 108, a filter medium 112,and a distal end cap 116. As best illustrated in FIG. 2, the proximalbase 108 further comprises an inlet receiver 120, a clamp 124, and anopening 128. The air filter 104 preferably is comprised of materialsthat are sufficiently durable and temperature resistant so as to retainits configuration during installation and operation when coupled withthe air inlet of the turbocharger.

The proximal base 108 generally is configured to support the air filter104 and provide an interface between the air filter 104 and air inlet ofthe turbocharger. The inlet receiver 120 is configured to receive theair inlet of the turbocharger, and the clamp 124 is configured to securethe air inlet within the inlet receiver 120 such that air is drawnthrough the filter medium 112 into an interior cavity 132 of the airfilter 104 and then is conducted through the opening 128 into the airinlet of the turbocharger. It will be appreciated that the inletreceiver 120 has a configuration, and the opening 128 has a diameter,suitable to accept the air inlet of the turbocharger. For example, theinlet receiver 120 may comprise any of a variety of additional ridges,or raised portions, so as to optimally engage the air inlet of theturbocharger. The specific configuration of the inlet receiver 120 andthe diameter of the opening 128 depend upon the particular make andmodel of the turbocharger for which the air filter 104 is to beutilized, and thus a wide variety of configurations and diameters may beincorporated into the air filter 104 without straying beyond the scopeof the present disclosure.

As best shown in FIGS. 1 and 3A, the proximal base 108 comprises a ridge136 and a recess 140 configured to receive a proximal end 144 of the airfilter 104. It is envisioned that any of a variety of fasteners (notshown) may be used to affix the proximal end 144 within the recess 140.In some embodiments, the ridge 136 may be molded to a wire support ofthe air filter 104. In some embodiments, the ridge 136 may be crimpedsuch that it folds onto and retains the wire support and the filtermedium 112 of the air filter 104. It will be appreciated that by thoseskilled in the art that, in some embodiments, fastening the filtermedium 112 to the proximal base 108 by way of the ridge 136 and therecess 140 renders the filter medium 112 irremovable from the air filter104.

It is envisioned that a user of the air filter 104 may periodicallyclean the filter medium 112 rather than replacing the air filter 104, asis typically done with conventional air filter systems. In someembodiments, a method for cleaning the filter medium 112 comprisesremoving the air filter 104 from the air inlet of the turbocharger,inserting a water hose through the opening 128 into the interior cavity132 of the filter, and spraying water so as to flush contaminants fromthe filter medium 112. In some embodiments, the method for cleaning theair filter 104 comprises utilizing a high pressure air hose in lieu ofthe water hose. In some embodiments, the method for cleaning the airfilter 104 comprises spraying water onto the exterior of the filtermedium 112, such that the water and contaminants drain from the exteriorof the filter medium 112. Other cleaning methods will be apparent tothose skilled in the art without deviating from the spirit and scope ofthe present disclosure.

As discussed above, the proximal end 144 of the filter medium 112 isfastened to the proximal base 108 by way of the ridge 136 and the recess140. The distal end cap 116 may be similarly affixed to the filtermedium 112 by way of any of a variety of fasteners (not shown). In someembodiments, the distal end cap 116 may be molded to a wire support ofthe filter medium 112, as discussed herein. In some embodiments, thedistal end cap 116 may be crimped around its peripheral edge such thatit folds onto and retains the wire support and the filter medium 112 ofthe air filter 104. In some embodiments, a simple nut and bolt may beused to attach the filter medium 112, the wire support, and the distalend cap 116 onto the proximal base 108 such that the proximal end 144 isheld fixed within the recess 140. Any of a variety of fastening meansmay be practiced for attaching the filter medium 112, the wire support,and the distal end cap 116 onto the proximal base 108 without deviatingfrom the spirit and scope of the present disclosure. Further, the distalend cap 116 preferably is comprised of a material which is sufficientlyhard so as to retain the filter medium 112 in the desired configurationand support the air filter 104 when coupled to the air inlet of theturbocharger. The filter medium 112 is also preferably durable enough towithstand repeated cleaning and use, as discussed herein.

As discussed above, the wire support may be incorporated into the filtermedium 112 so as to provide additional strength and durability to theair filter 104, thereby facilitating periodic cleaning and reusing theair filter 104 instead of discarding the filter after each application.In some embodiments, the filter medium 112 may be positioned between thewire support and one or more layers of a reinforcing material. Forexample, the wire support may comprise a wire screen positioned on anouter surface and an inner surface of the filter medium 112. In someembodiments, the wire screens may be comprised of powder-coated aluminumscreen wire that is co-pleated along with the filter medium 112 so as toreinforce the air filter 104. In some embodiments, the inner surface ofthe filter medium 112 may comprise a stronger mesh reinforcement whichis similar to those incorporated into Diesel filter applications. Insome embodiments, additional or alternative reinforcements may beprovided, as will be apparent to those skilled in the art.

In the embodiment of the air filter 104 illustrated in FIGS. 1-3, theproximal base 108 has a diameter substantially equal to the diameter ofthe distal end cap 116. In some embodiments, however, the proximal base108 may have a larger size than the size of the distal end cap 116. Itshould be understood that the air filter 104 of the present disclosureis not limited to the exact shape illustrated in FIGS. 1-3, but rather,may include a wide variety of generally cylindrical shapes, generallycircular, oval, round, curved, or other closed perimeter shapes, thatprovide a relatively large surface area of the filter medium 112. Insome embodiments, the filter medium 112 may comprise various heightsother than as shown in FIGS. 1-3, as well as comprising inversecone-shapes. In some embodiments, the air filter 104 may compriseinverted filter cones inserted so as to increase air flow through thefilter medium 112.

In the embodiment illustrated in FIG. 1, the distal end cap 116comprises a first opening 148 aligned with a screw mechanism 152 of theclamp 124. A second opening 150 in the proximal base 108 is also alignedwith the screw mechanism 152, as shown in FIG. 2. It will be appreciatedthat the screw mechanism 152 is configured to enable a user to tightenthe clamp 124 during installation of the air filter 104 onto the airinlet of the turbocharger. Alternatively, the user may use the screwmechanism 152 to loosen the clamp during removal of the air filter 104from the turbocharger.

FIG. 4 illustrates a perspective view of the clamp 124 in absence of theair filter 104. The clamp 124 comprises a metal band 156 including aperforated portion 160 which is received by the screw mechanism 152. Theperforated portion 160 is configured to receive a worm gear, or othersimilar component within the screw mechanism 152 capable of engaging theperforated portion 160, such that when the worm gear is turned the metalband 156 is accordingly tightened or loosed. A drive head 154 isconfigured to receive a tool suitable for turning the worm gear. Themetal band 156 preferably comprises 301 stainless steel or other similarmaterial. In some embodiments, the metal band 156 may be galvanized. Asbest illustrated in FIGS. 2 and 4, the screw mechanism 152 is disposedin a substantially perpendicular orientation relative to a circumferenceof the metal band 156. The substantially perpendicular orientationfacilitates engaging the screw mechanism 152 with an appropriate toolpositioned at substantially a right angle relative to the circumferenceof the metal band 156.

The first opening 148 and the second opening 150 facilitate tighteningand loosening the clamp 124 by extending an appropriate tool into thefirst opening 148, through the interior cavity 132, and into the secondopening 150 so as to engage the screw mechanism 152. As best illustratedin FIGS. 3A and 3B, a conduit 164 is positioned within the interiorcavity 132 and disposed between the first opening 148 and the secondopening 150. The conduit 164 is configured to guide the appropriate toolthrough the interior cavity 132 to the screw mechanism 152. The conduit164 further serves to prevent unfiltered air from entering through thefirst and second openings 148, 150 and into the air inlet of theturbocharger.

FIG. 5 illustrates a perspective view of an exemplary use environment168 wherein a screw driver 172, or other similar appropriate tool, isextended into the first opening 148, through the conduit 164, andthrough the second opening 150 so as to adjust the clamp 124 by way ofturning the drive head 154 of the screw mechanism 152. FIG. 6illustrates a perspective view of an exemplary use environment 176wherein a wrench 180 is being used to turn a driver 184 so as to adjustthe clamp 124 by way of turning the screw mechanism 152. In theenvironment 168 of FIG. 6, the driver 184 extends into the first opening148, through the conduit 164 in the interior cavity 132, through thesecond opening 150, and engages with the drive head 154 of the screwmechanism 152. Those skilled in the art will appreciate that accessingthe screw mechanism 152 by way of the first opening 148 and the secondopening 150 advantageously enables the inlet receiver 120 of the airfilter 104 to be inset into the scroll of the turbocharger and thentightened onto the air inlet without the user having to apply force tothe air filter 104 in an attempt expose the proximal base 108 and accessthe clamp 124.

As best shown in FIG. 2, the filter medium 112 circumferentiallysurrounds the interior cavity 132, such that the filter medium 112creates an exterior perimeter of at least a portion of the interiorcavity 132. As mentioned above, the exterior shape may be generallycircular, oval, conical, or otherwise shaped to improve the surface areaavailable for air flow passage for a given volume of the interior cavity132. The shape may be consistent along a longitudinal length, asillustrated in FIGS. 1-3, or may vary along the length. For example, theouter profile may taper from the proximal base 108 to the distal end cap116 so as to resemble a cone-shape, as discussed herein.

As will be appreciated by those skilled in the art, the filter medium112 provides a surface area through which to pass an air stream andentrap particulate matter and other contaminates so as to prevent themfrom entering into the air inlet of the turbocharger. As such, thefilter medium 112 may be comprised of paper, foam, cotton, spunfiberglass, or other known filter materials, woven or non-wovenmaterial, synthetic or natural, or any combination thereof. The filtermedium 112 may be pleated, as illustrated in FIGS. 1-3, or otherwiseshaped or contoured so as to increase the surface area for passing theair stream to be cleaned. In some embodiments, the filter medium 112 maycomprise a combination of materials to create a hybrid filter medium. Insome embodiments, the filter medium 112 may further comprise oil toenhance the air cleaning properties of the filter medium. Further, someembodiments may include a depth loading feature which gives the airfilter 104 a high airflow with a low restriction while providing largecontaminant holding capacities.

While the invention has been described in terms of particular variationsand illustrative figures, those of ordinary skill in the art willrecognize that the invention is not limited to the variations or figuresdescribed. In addition, where methods and steps described above indicatecertain events occurring in certain order, those of ordinary skill inthe art will recognize that the ordering of certain steps may bemodified and that such modifications are in accordance with thevariations of the invention. Additionally, certain of the steps may beperformed concurrently in a parallel process when possible, as well asperformed sequentially as described above. To the extent there arevariations of the invention, which are within the spirit of thedisclosure or equivalent to the inventions found in the claims, it isthe intent that this patent will cover those variations as well.Therefore, the present disclosure is to be understood as not limited bythe specific embodiments described herein, but only by scope of theappended claims.

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 15. A method foran air filter to mount onto air inlets of turbochargers andsuperchargers, comprising: configuring a base comprising an inletreceiver to couple with an air inlet, the base including a firstopening; fastening a filter medium to the base, the filter mediumconfigured to remove particle contaminates from air drawn into the airinlet; fastening a cap to the filter medium opposite of the base, thecap including a second opening; extending a conduit from the firstopening in the base to the second opening in the cap; configuring aclamp to secure the air inlet within the inlet receiver; and placing theclamp onto the inlet receiver.
 16. The method of claim 15, whereinextending the conduit further comprises positioning the conduit withinan interior cavity of the air filter, such that unfiltered air isprevented from entering through the first opening and the second openinginto the air inlet.
 17. The method of claim 15, wherein configuring theclamp further comprises configuring a screw mechanism of the clamp whichis operable by way of a suitable tool passed through the second openingin the cap, the conduit, and the first opening in the base.
 18. Themethod of claim 17, wherein placing the clamp further comprises aligningthe screw mechanism with the first opening, the conduit, and the secondopening so as to facilitate operation of the clamp by way of thesuitable tool.